Process of making paper articles



Feb. 25, 1930. V N. E. FUNK j 1,748,761

PROCESS OF MAKING PAPER ARTICLES Original Filed Oct. 5, 1927 2 Sheets-Sheet 1 INVENTOR gels? E. Fuv ak niMfa/vl ATTORN EY S Feb. 25, 1930- N. E. FUNK 1,748,761

" PROCESS OF MAKING PAPER ARTICLES Driginal Filed Oct. 5, 1927 B Sheets-Shee 2 Ehwntoz 7Zezsov z F. Funk Patented Feb. 1930 IUNrraD s'rA'rss PATENT OFFICE.

mason a. some or NEW YORK, n. Y., assrenoa arc-rum: :o. many, or miiw YORK coum,nnwvonx raocnss or name urea an'rrotns Original application fled October 8, 1887, Serial No. $558,658. Divided and this application 'flled lay 81, j

. 1928. Serial No. 878,884.

This invention relates to improvements in processes for the manufacture of paper articles and is a divisional application of applicants copending ap lication Ser. No. 223,659 filed October 3-, 192

It is a particular object of this invention to provide a rocess for making pa er articles of a plura ity of plies of expansib e paper. This invention is particularly applicable to egg flats, especially those with cross corrugations, and those flats for use 1n the packing of other fragile articles. a

In the past-it"has been proposed to make such flats of cardboard or heavy paper by stamping the su porting projections out of said material. ince nelther cardboard nor paper will stretch the obvious result is that the material will 'break at the points of deformation, and will be useless for the purpose intended. Furthermore, the fibres of wa s ten to return to normal position after de ormation,thereby causing the projections on the'flat to assume irregular positions. For these reasons none of the early devices were, to a plicants knowledge, commercially success ul or commonly used. A later development of the art to overcome some of the above mentioned deficiencies, was to manufacture said flats from loose fibres such as pulp, by pressing them in sheet form into the desired shape, while damp,-and then drying. But though this development overcame some of the objections to earlier devices, it was open to objections of a different nature although fully as serious. I The main objections to this type of flat are that in the first place there is not sufiicient cohesion between the fibres to withstand any substantial pressure, and secondly, and of greater weight, that, pulp, having a ve strong affinity for water, they rapidly absor moisture from the cool dam air to which it the are usually subjected, ecoming limp an useless for the purpose intended.

To overcome these objections as well as objections to earlier devices, applicant has formed a flat of expansible paper, an exam- .ple of which is the well-known crepe paper.

I paper ltself does not stretch but that the inaper having'set once in a definite position 1n the ori inal manufacture of the paper al- This type of paper contains numerous small crinkles whic if any stress is put upon the paper, straighten out, giving greater surface to the paper. It must be understood that the crease in size is due. to the smoothing out' of said crinkles.

Likewise in forming paper articles such as cu s, plates etc. from 'a plurality of plies or or inary paper where an embossing operation is necessary to form the object desired, there is a great deal of difliculty in obtaining a proper e go on the object for the reason that during the embossin operation the several plies slip on each ot er whereby the edges are staggered. According to ap licants invention an edge of uniform thic ess is obtained due to the fact that the expansibility of the aper provides for the slippage taking place uring the embossing operation.

In practising this invention a plurality of layers of such paper are superimposed and united by a water-proof glue, for which purose a so ution of sodium silicate is preferred or the reason that it is very stable, sets very hard and is flexible when set. After the layers of paper are so bound and before the glue is set 1: ey are subjected to an embossing o eration. Due to the fact that the glue is st1ll damp, the various layers are movable relative'to each other whereby allowance is made for necessary slippage between layers when making curved surfaces. In addition to this, the strains to which the paper is subjected during the embossing operation are taken care of by the expansibility of the paper, as pointed'out above, and the finished article presents a substantially smooth appearance.

a The thickness of paper used is governed by the weight ofarticle desired. All the layers maybe of the same thickness or the middle layers may be of greater thickness than the outer layers, but whatever be the thickness, the paper must be creped or made expansible bysome other method, or the product ,will be unsatisfactory.

This process is illustrated in the accompanying drawings in which Fig. 1 is a side view of an arrangement of mechanisms "for carrying out the process.

. Fig. 2 represents a plan view ofaflat.

, Fig. 3 is a vertical section of a packing unit in use slightly enlarged to show the plies of the flat... 7

Referring to the drawings in detail, A,

' supplying a surplus of paper so that when the raised portions are embossed the paper is not. fractured. In like manner, the paper from roll C passes between creping rollers 5 and 6. The paper from roll B being the middle layer, after passing through crepin'g rollers. 1 and 2 passes around roller 25 in a vat 26 filled with sodiumsilicate solution of desired consistency, and from there. passes through rollers 24 which remove the excess of adhesive which drops back into the tank. Rollers 22 and 23 are pressing rollers through which the strips pass simultaneously. 7 and 8 are feedrollers which feed the combined strips from rollers 22 and 23 to platen 11.-

13 is a knife reciprocated' by eccentric 17 on the shaft of disc 19 which is in contact with the driving disc 20. Mounted adjacent the lmife 13 is a stop 12 which binds the strips against the platen 11 on the downward metion of the knife 13 thereby stopping their movement until the knife has cut off the desired length. Rollers 9 and 10 are feed rollers which move the paper onto plate 15 which is the female member of a die, and which is heated by steam or other common means.

The male member of the die 14 is recipro:

cated by an eccentric 16 on the shaft of the disc 18 which is connected to the driving disc 20. 21 is a conveyor for removing the finished article.

As shown in Figs. 2 and 3,. the finished flat is made up of three pliesbf material, although it is not limited to this number and is corrugated transversely and longitudinally, the corrugations 29 being pressed downwardly and intersecting to form sections 30 of which there'are usually thirty-six to a fiat. Centrally located in each section is a convex portion 31 pressed upwardly from the flat. In the centerof each convex portion is a concavity 32 formed by pressing the convex portion in the opposite direction.

A further advantage of these flats is that they are very light thereby reducing shipping expenses both when in use and empty in nested relation.

Having thus fully described the invention as practiced, to which description, however, the inventionis not limited, it only being the preferred form and capable of various modifications and alterations within the scope of when shipped the invention, what is claimed as new is:

1. The process of making embossed paper Y articles in a continuous operation -cons1stmg in entraining a plurality of plies of paper over rollers, creping each ply, applying a water-proof glue to both sides of the inner ply, pressing the plies together without dry.- ing the glue, cutting the plies into proper length, embossing each length while the glue is still wet, and simultaneously drying the' glue.

I 2. The process ofmakmg embossed paper artlcles in a continuous operatlon consistm inentraining a plurality ofplies of expans1-' ble paper over rollers, apply1ng a water-proof glue toboth sides of the inner ply, pressing the plies together without drying the glue, cutting the plies into proper length, embossing each length while the glue is still wet, and simultaneously drying the glue;

3. The process of making egg flats in a continuous operation consisting in entraining a plurality of plies of expansible paper over rollers, applying a water-proof glue to both sides of the inner ply, pressing the plies 5. The process of making egg flats com-- prisin the steps of binding together. with wet glhev a plurality of plies of crepe paper and embossing raised egg supporting portions on said plies while the glue is still wet whereby relative slippage. is provided between the several plies and the crinkles in the plies are smoothed out, at the same time applying heat to dry the glue and stiffen the combined plies in embossed condition.

In testimony whereof I have hereunto set.

my-hand.

NELSON E. FUNK. 

